Gas turbine engine tip clearance control

ABSTRACT

A gas turbine engine is disclosed having a thermoelectric device capable of changing a tip clearance in a turbomachinery component. In one non-limiting form the turbomachinery component is a compressor. The thermoelectric device can be used in some forms to harvest power derived from a waste heat. The tip clearance control system can include a sensor used to determine a clearance between a tip and a wall of the turbomachinery component.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application 61/581,793, filed Dec. 30, 2011, and is incorporated herein by reference.

GOVERNMENT RIGHTS

The present application was made with the United States government support under Contract No. NB1201. The United States government has certain rights in the present application.

TECHNICAL FIELD

The present invention generally relates to gas turbine engine thermal devices, and more particularly, but not exclusively, to tip clearance control of the gas turbine engine.

BACKGROUND

Providing tip clearance in gas turbine engines remains an area of interest. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.

SUMMARY

One embodiment of the present invention is a unique tip clearance control system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for controlling tip clearance. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts an embodiment of a gas turbine engine having a tip clearance control system.

FIG. 2 depicts an embodiment of a tip clearance control system.

FIG. 3 depicts an embodiment of a tip clearance control system.

FIG. 4 depicts another embodiment of a tip clearance control system.

FIG. 5 depicts an embodiment of a tip clearance control system.

FIG. 6 depicts an arrangement of thermoelectric devices.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

With reference to FIG. 1, a gas turbine engine 50 is shown having a number of turbomachinery components useful in the generation of power, such as but not limited to providing power for an aircraft 52. As used herein, the term “aircraft” includes, but is not limited to, helicopters, airplanes, unmanned space vehicles, fixed wing vehicles, variable wing vehicles, rotary wing vehicles, unmanned combat aerial vehicles, tailless aircraft, hover crafts, and other airborne and/or extraterrestrial (spacecraft) vehicles. Further, the present inventions are contemplated for utilization in other applications that may not be coupled with an aircraft such as, for example, industrial applications, power generation, pumping sets, naval propulsion, weapon systems, security systems, perimeter defense/security systems, and the like known to one of ordinary skill in the art.

The gas turbine engine 50 includes a compressor 54, combustor 56, and turbine 58 which together operate to produce the power. Air or other suitable working fluid enters to the compressor 54 whereupon it is compressed and routed to the combustor 56 to be mixed with a fuel. The combustor 56 is capable of combusting the mixture of fuel and working fluid. The turbine 58 extracts work from the products of combustion that result from the combustion of fuel and working fluid. In some forms the flow stream exiting the turbine can be routed to a nozzle to produce thrust.

The gas turbine engine 50 can take a variety of forms other than that depicted in the illustrated embodiment. For example, though the embodiment is shown as a single spool engine, other embodiments can include greater numbers of spools. The gas turbine engine 50, furthermore, can take the form of a turbojet, turboprop, turboshaft, or turbofan engine and can be a variable cycle and/or adaptive cycle engine. The gas turbine engine 50 is also depicted in the illustrated embodiment as an axial flow engine, but in other embodiments it can be a radial flow engine and/or a mixed radial/axial flow engine. In short, any variety of forms are contemplated for the gas turbine engine 50.

The gas turbine engine 50 can be coupled with a tip clearance control system 60 which can be use to control a clearance between a tip of an airflow member, such as a moving blade in a turbomachinery component like the compressor 54, and a wall that forms a flow path through the turbomachinery component that is in proximity to the tip of the airflow member. The discussion that follows will often refer to a blade of the turbomachinery component which is but one embodiment of the present application. Therefore, no limitation is hereby intended as to the type of air flow member that the tip clearance control system 60 can be used with. For example, the tip clearance control system could also be used with a vane of the gas turbine engine 50, such as but not limited to a variable vane. Thus, unless stated to the contrary, the term blade and vane can be used interchangeably to identify an air flow member disposed within the turbomachinery component. In one form the tip clearance control system 60 can be used to regulate a temperature of the wall thus changing the thermal growth of the wall to affect a clearance between the airflow member and the wall. The tip clearance control system 60 can be active during all or portions of operation of the gas turbine engine and in one form is capable of anticipating transient events to avoid and/or mitigate a clearance or contact between the blade and the wall.

The controller 60 can be comprised of digital circuitry, analog circuitry, or a hybrid combination of both of these types. Also, the controller 60 can be programmable, an integrated state machine, or a hybrid combination thereof. The controller 60 can include one or more Arithmetic Logic Units (ALUs), Central Processing Units (CPUs), memories, limiters, conditioners, filters, format converters, or the like which are not shown to preserve clarity. In one form, the controller 60 is of a programmable variety that executes algorithms and processes data in accordance with operating logic that is defined by programming instructions (such as software or firmware). Alternatively or additionally, operating logic for the controller 60 can be at least partially defined by hardwired logic or other hardware. In one particular form, the controller 60 is configured to operate as a Full Authority Digital Engine Control (FADEC); however, in other embodiments it may be organized/configured in a different manner as would occur to those skilled in the art. It should be appreciated that controller 60 can be exclusively dedicated to tip clearance control, or may further be used in the regulation/control/activation of one or more other subsystems or aspects of aircraft 52.

The aircraft 52 and/or gas turbine engine 50 can be capable of operating at a variety of conditions in which the tip clearance control system 60 may be exercised. In the illustrated embodiment a sensor 62 is included that can be used to measure/estimate/assess/etc a number of conditions/states/etc. In one form the sensor 62 can be used to measure aircraft flight condition such as speed and altitude, to set forth just two non-limiting examples. The sensor 62 can output any variety of data whether sensed or calculated. For example, the sensor 62 can sense and output conditions such as static temperature, static pressure, total temperature, and/or total pressure, among possible others. In addition, the sensor 62 can output calculated values such as, but not limited to, equivalent airspeed, altitude, and Mach number. Any number of other sensed conditions or calculated values can also be output.

The sensor 62 can also take the form of a proximity sensor useful in providing information regarding a tip clearance between a blade of the turbomachinery component and an adjacent wall. Such information is used by the controller 60 in the regulation of the tip clearance between a moving blade and a wall of the turbomachinery component. In one form the sensor 62 provides real time signals of the distance such that a plurality of distance values as a function time are generated. The sensor 62 can either provide raw sensed information, either analog or digital, or it can provide a computed value. Furthermore, the sensor 62 can output information in a variety of formats and can further be conditioned using additional electronics and/or software. In some forms the sensor 62 can provide multiple useful signals to the controller 60 such as a minimum distance, maximum distance, time varying distance, historical information, etc. Alternatively and/or additionally such information can be computed in the controller 60 or other alternative and/or additional module. No matter the form, content, etc, the sensor 62 is capable of providing sufficient information that enables the controller 60 to regulate the temperature of the wall such that a clearance between the wall and the blade(s) is regulated.

The proximity sensor 62 can be a capacitive sensor or optical sensor, among potential others useful for detecting a tip clearance. The sensor 62 can be configured to withstand elevated temperatures of a gas turbine engine 50, whether in rotating compressor equipment or turbine components, and can be resistant chemical attack as well as resistant to deposition of solids onto its exposed surfaces. Further, the sensor 62 can also be resistant to electromagnetic interference, vibration, noise, and shock, among any number of other characteristics.

Turning now to FIGS. 2 and 3, one form of the tip clearance control system 60 is depicted which is coupled to a thermoelectric device 64 for changing a temperature of a portion 66 of a turbomachinery component. The thermoelectric device 64 can be powered by the engine 50 or a vehicle power system such as may be coupled with an airframe of an aircraft. The temperature of the component can determine its relative size/orientation such that in one form at higher temperatures the component is relatively larger than at low temperatures. The component can be heated by the thermoelectric device to provide a larger size component and cooled to provide a relatively smaller sized component. In this way the thermoelectric device can be a fully reversible system that can either heat or cool the component. Of course, in some embodiments the thermoelectric system can include or be supplemented with circuitry, software logic, electrical components, etc. that provide either a heating or a cooling, but not both. It will be understood that such a system will still include at its core a thermoelectric device that can be operated in both directions were it not for the additional or supplemental configuration. When coupled with changing size/orientation of the blade and/or rotor, the tip clearance control system can selectively heat and cool the component to affect a tip clearance between the component and the blade.

The particular type of thermoelectric device shown in FIGS. 2 and 3 includes a configuration of alternating semiconductor materials, and specifically alternating p-type and n-type semiconductors. The type of device depicted in these figures can also be used in any of the embodiments herein. Any variety of material types can be used to form the thermoelectric device. The thermoelectric devices described herein can take the form of a thermoelastic film which can have any variety of shapes and sizes. Any variety of thermoelectric effects, and accompanying configurations, can be employed by the thermoelectric device to alter a temperature of the turbomachinery component to change a tip clearance between the wall 66 and the blade 70. To set forth just a few examples, thermoelectric devices that rely the Seebeck effect, Peltier effect, and Thomson effect, are all contemplated within the scope of the application.

Thermoelectric heaters/coolers can be coupled with the controller 60 in a way that an electric state of the thermoelectric device 64 can be regulated to control a tip clearance. The thermoelectric device 64 of the illustrated embodiments include a radially inner substrate 78 and a radially outer substrate 80 to which the p-type semiconductor 74 and n-type 76 are coupled. The radially inner substrate 78 is coupled with electrical leads 82 and 84 between which can be a potential difference. The leads 82 and 84 are coupled to the substrate 78 in a way that creates a pathway for current flow through the thermoelectric device 64. In one form the potential difference between the leads 82 and 84 can be the result of a waste heat being captured by the thermoelectric device and in others a potential difference can be applied across the leads to encourage a heat transfer in a certain direction, such as whether to cool or heat the wall 66, to set forth just two non-limiting examples. In still other examples the potential difference applied across the leads can be the result of electric power provided by a thermoelectric device disposed elsewhere whether associated with the vehicle and/or gas turbine engine. In some forms the electric power can originate from a battery that is charged using a thermoelectric device disposed elsewhere. In one non-limiting example, a waste heat can be captured by one thermoelectric device and the electric power stored using a storage device such as but not limited to a battery. Alternativey and/or additionally the waste heat can be used to directly regulate power across another thermoelectric device. In still other forms a waste heat can be stored for purposes other than strictly tip clearance.

Though a number of p-type 74 and n-type 76 are depicted in the illustrated embodiment, more or fewer can also be used. The semiconductors are alternated along the flow stream direction in a pattern that alternates between the types of semiconductors, but any other pattern is also contemplated. In some cases, individual pairings of p-type 74 and n-type 76 semiconductors can be combined with other individual pairings in any number of combinations to be used in the thermoelectric device 64.

The thermoelectric device 64 can extend over the entire periphery of the engine case in some embodiments, while in other embodiments the device 64 may only extend over part of the engine case. In some forms a number of thermoelectric devices 64 can be located about the engine case at the same or different axial stations. In still other alternative and/or additional embodiments, the thermoelectric devices 64 can be configured such that portions of the device distributed around the engine case can be selectively operated. For example, a portion in one circumferential region can be activated to provide one level of heat transfer, while a portion in another circumferential region can be activated to provide another level of heat transfer, whether the heat transfer is a heating or a cooling. Various modules can also be used, which in whole or in part can be operated similarly to provide localized heat transfer to the engine case, again whether that heat transfer is a heating or cooling.

Thermal transfer member 86, which in the illustrate embodiment is in the form of fins but other embodiments need not include fins, can be used to assist in transferring heat between a medium 88 and the wall 66. For example, the medium can be a flowing working fluid, such as a cooling air, to aid in heat transfer when the thermoelectric device 64 is in operation. The thermal transfer fins 86 of the illustrated embodiment can take a variety of shapes and sizes whether generally referred to as a “fin” or other device useful in transferring heat with the medium 88. The thermal transfer fins 86 can cover the entirety of the thermoelectric device 64 or only a portion thereof.

Turning now to FIG. 4, another embodiment of the tip clearance control system 60 is shown. The thermoelectric device 64 is shown located above a compressor blade 70 just upstream of a diffuser 90. The thermoelectric device 64 can include a thermal mass 92 that assists in the transfer of heat between the thermoelectric device 64 and a medium in contact with the thermal mass 92. The thermal mass can take a variety of forms such as a cold plate and/or fins. In any of the embodiments herein, any of the fins, cold plates,

FIG. 5 shows a view of an embodiment of the tip clearance control system 60 in which a number of thermoelectric devices in the form of modules 94 are spaced about the circumference of a gas turbine engine case 96. The modules 94 are evenly distributed in a single row round the circumference of the case 96, but other arrangements are also contemplated. For example, a higher concentration of modules 94 can be located at certain circumference locations than other. Some modules 94 can be axially offset from others, while in other embodiments additional rows can also be added. The modules 94 can be controlled individually, in clusters, or as a whole. Furthermore, the modules 94 can have different sizes, configurations, capabilities, etc even though the illustrated embodiment depicts similar modules. In sum, any variety of physical and control arrangements as well as size and capabilities are contemplated.

The thermoelectric devices described herein can be affixed to a casing or other suitable gas turbine engine structure through a variety of techniques. In one non-limiting form the thermoelectric devices can be affixed via a thermally conductive bond. The thermoelectric devices can be affixed to the bond at discrete locations around the casing or other suitable structure, or for a full circumferential length around the casing, etc.

The thermoelectric devices described herein can be powered using a variety of power sources. In one non-limiting embodiment the electrical power originates from a generator driven by the gas turbine engine 50. In other additional and/or alternative embodiments the thermoelectric device can be powered by an energy storage device, such as a battery. In still further additional and/or alternative forms the thermoelectric devices can be powered by other thermoelectric devices, some of which can be in thermal communication with the gas turbine engine.

FIG. 6 depicts an arrangement of thermoelectric devices used in the gas turbine engine 50 in which one device 98, or a set of devices is used to provide power to another device 100, or set of devices. In the illustrated embodiment two separate rows of thermoelectric devices are shown in each of the compressor 54 and the turbine 58. The devices 98 shown as thermally coupled with the turbine 58 in the illustrated embodiment can be used to generate power to drive the devices 100 shown as thermally coupled with the compressor 54. Though the illustrated embodiment depicts flowing power from devices in a turbine area to devices in a compressor area, other locations and directions of power transfer are contemplated. In this way power generated using a thermoelectric devices in one location of the gas turbine engine can be used to power thermoelectric devices in another location. To set forth another non-limiting example, one embodiment would be to coupe the tip clearance control system with a set of thermoelectric modules attached elsewhere to the engine or to hardware mounted on the engine such as a bleed air duct.

In any of the embodiments described in the application, the tip clearance, or gap, can be set during manufacture of the turbomachinery component and/or gas turbine engine to favor a certain flight condition, engine operating environment, operational demands, etc. For example, the tip clearance can be set to accommodate a snap deceleration in which a tip clearance is typically the tightest owing to a faster cooling of the casing than the rotating disc and blades. In this case the gap can be manipulated during cruise by supplying power to the thermoelectric devices.

Though various of the illustrated embodiments discussed above depicts controlling a tip clearance e of a compressor section of the gas turbine engine, the tip clearance control system 60 could also be used in the turbine section as well. The thermoelectric device is shown as being coupled at a radially outer portion of the flow path 68 but other locations are also contemplated to affect a change in a tip clearance between a blade 70 and wall 66.

One aspect of the present application includes an apparatus comprising a gas turbine engine flow path wall forming a boundary for the flow of a working fluid through a turbomachinery component having an airfoil shaped component during operation of a gas turbine engine, a thermoelectric device in thermal communication with the gas turbine engine flow path wall, and a control module structured to regulate the thermoelectric device to influence a thermally induced gap between the gas turbine engine flow path wall and the airfoil shaped component.

One feature of the present application provides wherein the control module can regulate the thermoelectric device to selectively heat the gas turbine engine flow path wall in a first mode of operation and selectively cool the gas turbine engine flow path wall in a second mode of operation.

Another feature of the present application provides wherein the thermoelectric device is in thermal communication with protrusions that project into a cooling space.

Still another feature of the present application provides wherein the control module regulates the thermoelectric device on basis of a sensed clearance derived from a proximity sensor.

Yet still another feature of the present application provides wherein the proximity sensor operates according to one of capacitive principles and optical principles.

Still yet another feature of the present application provides wherein in a first mode of operation the thermoelectric device is used to generate a potential difference based upon a waste heat of the gas turbine engine.

A further feature of the present application provides wherein the thermoelectric device includes a plurality of P-Type and N-Type semiconductors.

A still further feature of the present application provides wherein a first P-Type semiconductor and a first N-Type semiconductors are located at different flow stream locations, wherein the plurality of semiconductors extend around the full circumference of the gas turbine engine flow path wall, and wherein a thermally conductive bond is used to coupled the thermoelectric device with the turbomachinery component.

Another aspect of the present application provides an apparatus comprising a gas turbine engine flow component having a flow path defined by a wall and in which is disposed a blade used to alter a direction of a flow through the component, and a tip clearance control system configured to change a distance between the wall and the blade, the clearance control system having an electrical device that includes a junction between dissimilar materials in thermal communication with the wall wherein a potential difference across the junction is related to a temperature difference across the junction.

Still another feature of the present application provides wherein the tip clearance control system is structured to regulate a voltage across the electrical device to perform one of heating the gas turbine engine flow component and cooling the gas turbine engine flow component.

Yet still another feature of the present application further includes a sensor in feedback relation with the tip clearance control system, the sensor operable to provide a regulation variable such that the distance between the wall and the rotatable blade is controlled.

Still yet another feature of the present application provides wherein the sensor generates a signal representative of a distance between the wall and at least one of the blades.

A further feature of the present application provides wherein the proximity sensor includes one of a capacitor and an optical sensor.

A still further feature of the present application provides wherein during operation of the tip clearance control system, waste heat from the gas turbine engine is used to power the thermoelectric device.

A yet still further feature of the present application further includes an energy storage device to harvest potential difference generated by the waste heat.

Still another aspect of the present application provides an apparatus comprising a gas turbine engine having rotatable blade and an end wall, and means for thermoelectrically changing a distance between the blade and the end wall.

Yet still another aspect of the present application provides a method comprising operating a gas turbine engine to produce a flow stream through a turbomachinery component of the gas turbine engine, moving a bladed row of airflow members in the turbomachinery component, the flow stream traversing through the bladed row; flowing an electrical current across a junction of two dissimilar materials to produce a heating response, changing a clearance between a wall and the tips of the bladed row in proximity with the wall.

A feature of the present application provides wherein the flowing occurs as a result of a thermoelectric phenomena, and the flowing results in a cooling of a wall member of the turbomachinery component.

Another feature of the present application further includes changing a tip clearance of the turbomachinery component.

Still another feature of the present application further includes determining a tip clearance to aid in the changing a tip clearance.

Yet still another feature of the present application provides wherein the determining includes sensing the tip clearance with a sensor that operates according to one of capacitive or optical principles.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary. 

What is claimed is:
 1. An apparatus comprising: a gas turbine engine flow path wall forming a boundary for the flow of a working fluid through a turbomachinery component having an airfoil shaped component during operation of a gas turbine engine; a thermoelectric device in thermal communication with the gas turbine engine flow path wall; and a control module structured to regulate the thermoelectric device to influence a thermally induced gap between the gas turbine engine flow path wall and the airfoil shaped component.
 2. The apparatus of claim 1, wherein the control module can regulate the thermoelectric device to selectively heat the gas turbine engine flow path wall in a first mode of operation and selectively cool the gas turbine engine flow path wall in a second mode of operation.
 3. The apparatus of claim 1, wherein the thermoelectric device is in thermal communication with protrusions that project into a cooling space.
 4. The apparatus of claim 1, wherein the control module regulates the thermoelectric device on basis of a sensed clearance derived from a proximity sensor.
 5. The apparatus of claim 4, wherein the proximity sensor operates according to one of capacitive principles and optical principles.
 6. The apparatus of claim 1, wherein in a first mode of operation the thermoelectric device is used to generate a potential difference based upon a waste heat of the gas turbine engine.
 7. The apparatus of claim 1, wherein the thermoelectric device includes a plurality of P-Type and N-Type semiconductors.
 8. The apparatus of claim 7, wherein a first P-Type semiconductor and a first N-Type semiconductors are located at different flow stream locations, wherein the plurality of semiconductors extend around the full circumference of the gas turbine engine flow path wall, and wherein a thermally conductive bond is used to coupled the thermoelectric device with the turbomachinery component.
 9. An apparatus comprising: a gas turbine engine flow component having a flow path defined by a wall and in which is disposed a blade used to alter a direction of a flow through the component; and a tip clearance control system configured to change a distance between the wall and the blade, the clearance control system having an electrical device that includes a junction between dissimilar materials in thermal communication with the wall wherein a potential difference across the junction is related to a temperature difference across the junction.
 10. The apparatus of claim 9, wherein the tip clearance control system is structured to regulate a voltage across the electrical device to perform one of heating the gas turbine engine flow component and cooling the gas turbine engine flow component.
 11. The apparatus of claim 9, which further includes a sensor in feedback relation with the tip clearance control system, the sensor operable to provide a regulation variable such that the distance between the wall and the rotatable blade is controlled.
 12. The apparatus of claim 11, wherein the sensor generates a signal representative of a distance between the wall and at least one of the blades.
 13. The apparatus of claim 9, wherein the proximity sensor includes one of a capacitor and an optical sensor.
 14. The apparatus of claim 9, wherein during operation of the tip clearance control system, waste heat from the gas turbine engine is used to power the thermoelectric device.
 15. The apparatus of claim 9, which further includes an energy storage device to harvest potential difference generated by the waste heat.
 16. An apparatus comprising: a gas turbine engine having rotatable blade and an end wall; and means for thermoelectrically changing a distance between the blade and the end wall.
 17. A method comprising: operating a gas turbine engine to produce a flow stream through a turbomachinery component of the gas turbine engine; moving a bladed row of airflow members in the turbomachinery component, the flow stream traversing through the bladed row; flowing an electrical current across a junction of two dissimilar materials to produce a heating response; changing a clearance between a wall and the tips of the bladed row in proximity with the wall.
 18. The method of claim 17, wherein the flowing occurs as a result of a thermoelectric phenomena, and the flowing results in a cooling of a wall member of the turbomachinery component.
 19. The method of claim 18, which further includes changing a tip clearance of the turbomachinery component.
 20. The method of claim 19, which further includes determining a tip clearance to aid in the changing a tip clearance.
 21. The method of claim 20, wherein the determining includes sensing the tip clearance with a sensor that operates according to one of capacitive or optical principles. 